BR112017010019B1 - METHOD OF FORMATION OF A BODY IN CUP SHAPE FOR A DRINK CAPSULE - Google Patents

Abstract

a method of forming a cup-shaped body for a beverage capsule. a method of forming a cup-shaped body for a beverage capsule comprising the steps of: a) in a first stage, embedding a sheet of material into a cup-shaped body preform; and b) in a second stage, the transformation of the cup-shaped body preform into the cup-shaped body; wherein, after the first stage, the cup-shaped body preform comprises a base and a preformed sidewall extending from the base to a rim; wherein the preformed side wall comprises: a step extending outwardly near the rim; a primary sidewall section extending between the base and the outwardly extending step; and a secondary sidewall section extending between the outwardly extending step and the rim; wherein, in the second stage, the preformed side wall is deformed so that the cup-shaped body comprises the base and a side wall extending from the base to the rim; wherein the side wall comprises: an annular trough; a primary sidewall section extending between the base and the annular trough; and a second sidewall section extending between the annular trough and the rim.

Description

[0001] The present disclosure relates to a method of forming a cup-shaped body for a beverage capsule. The beverage capsule formed using the cup-shaped body can be used in a beverage preparation system of the type comprising a beverage preparation machine, wherein the beverage capsule is designed for insertion into the beverage preparation machine to allow a pressurized liquid to flow through the capsule so as to produce a beverage for interacting with beverage ingredients contained in the capsule.

Background

[0002] Beverage preparation systems comprising a beverage preparation machine and a capsule containing beverage ingredients are known in the art. Such a system is taught in EP 1700548, which discloses a capsule comprising a cup-shaped body and a closure foil member. The capsule is designed for insertion into a beverage production device in which a liquid under pressure enters the capsule in order to interact with the ingredients in the capsule to form a beverage, which is extracted for consumption. The capsule of EP 1700548 is provided with a dedicated sealing member to prevent a by-pass flow of water around the outside of the capsule in use. The sealing member is in the form of a hollow sealing member on the outer surface of the capsule, for example, in the form of a step, which is contacted in the closure of a closure member of the beverage preparation machine.

[0003] The present disclosure provides an alternative method of forming beverage capsule parts, which can be used as part of such a beverage preparation system. The beverage capsule can be economical to produce and provide an effective seal in use.

Disclosure Summary

[0004] The present disclosure provides a method of forming a cup-shaped body for a beverage capsule, comprising the steps of: a) in a first stage, embedding a sheet of material in a preform of cup-shaped body; and b) in a second stage, the transformation of the preform from a cup-shaped body to a cup-shaped body; wherein, after the first stage, the cup-shaped body preform comprises a base and a preformed sidewall extending from the base to a rim; wherein the pre-formed sidewall comprises: - a step which extends outwardly close to the rim; - a primary sidewall section extending between the base and the outwardly extending step; and - a secondary side wall section extending between the outwardly extending step and the rim; wherein, in the second stage, the preformed sidewall is deformed so that the cup-shaped body comprises the base and a sidewall extending from the base to the rim; wherein the side wall comprises: - an annular trough; - a primary sidewall section extending between the base and the annular trough; and - a second side wall section extending between the annular trough and the rim.

[0005] The second side wall section may define a ridge zone located radially outward from the annular trough and the ridge zone to be formed during the second stage by deforming the outwardly extending step and/or the second wall section side.

[0006] The outwardly extending step can be inclined by 90° with a central longitudinal axis of the cup-shaped body preform.

[0007] The primary sidewall section may comprise a frusto-conical section near the base.

[0008] The frusto-conical section of the primary sidewall section may be substantially or totally unaffected by the second stage transformation, and thus may form a frusto-conical section of the primary sidewall section.

[0009] The primary sidewall section may comprise a cylindrical section between the frusto-conical section and the outwardly extending step.

[0010] The secondary sidewall section may comprise a frusto-conical section, which preferably is divergent in the direction of the rim.

[0011] The annular trough may comprise an inner wall, an outer wall and a bottom. The outer wall can be angled relative to the bottom so that an inner angle at a junction between the bottom and the outer wall is 90° to 120°, preferably 105°. Thus, the seal with the closing member can be a tapered seal.

[0012] A bottom of the annular trough can be raised in relation to the frame. Alternatively, the bottom of the annular trough can be substantially flush with the rim.

[0013] The rim can be formed integrally with the cup-shaped body.

[0014] The rim can be formed by a rolled-up portion of the sidewall. The rim can be formed during the first stage of the drawing, when forming the cup-shaped body preform.

[0015] The annular trough may have an internal width of from 1.3 to 2.0 mm, preferably from approximately 1.5 mm to 1.8 mm.

[0016] The annular trough may have an inner diameter of 27.5 to 30.0 mm and an outer diameter of 29.3 mm to 32.5 mm.

[0017] The cup-shaped body preform may be formed from an integral sheet of material.

[0018] The cup-shaped body preform is preferably formed by deep embossing the sheet of material, more preferably a deep cold embossing of the sheet material.

[0019] Preferably, the sheet material comprises an aluminum material and may be substantially or entirely of an aluminum material (except lacquers and adhesive layers). A reference to aluminum includes aluminum alloys and the aluminum alloy may be, for example, grade 3005, 3105, 8011 or 8079. Preferably, the aluminum alloy will have a temper grade of 'O'.

[0020] Alternatively, the sheet material may comprise a laminated material, preferably a layer of aluminum laminated with one or more layers of polymer. In this case, after forming, one or more polymer layers are located towards the outside of the cup-shaped body and the aluminum layer is provided towards the inside of the cup-shaped body.

[0021] One or more polymer layers may comprise a single layer of a single polymer material or multiple layers of different polymer materials. When multiple layers of different polymer materials are used, each layer can be applied separately when forming the sheet of material. However, it is preferred that the multiple layers of different polymer materials are first formed into a multi-layer laminated polymer film, which then can be laminated to the aluminum layer by a suitable process, for example, adhesive lamination.

[0022] The polymer materials of one or more polymer layers may comprise materials selected from the group consisting of homopolymers, copolymers and mixtures thereof. By homopolymer is meant a polymer produced by the polymerization of a single monomer. By copolymer is meant a polymer produced by the polymerization of two or more monomers.

[0023] Suitable homopolymers include polyvinyl chloride (PVC), polypropylene (PP), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), polytetrafluoroethylene (PTFE), terephthalate polyethylene (PET), polychloroprene, polyisobutylene and polyamides.

[0024] Suitable copolymers include fluorinated ethylene propylene (FEP), an ethylene propylene diene monomer (EPDM), polyamides, thermoplastic copolyesters (TPC) and olefin block copolymers (OBC). These copolymers are preferably alternate copolymers or block copolymers. By alternating copolymer is meant a copolymer with regular alternating monomer units. By block copolymer is meant a copolymer comprising two or more homopolymer subunits linked by covalent bonds.

[0025] One or more polymer layers may also incorporate binding layers and/or one or more barrier layers for inhibiting the transmission of moisture and/or oxygen. A suitable barrier layer material is ethylene vinyl alcohol (EVOH).

[0026] Additionally, optionally, one or more lacquer layers or adhesive layers may be present in the sheet of laminated material. For example, an adhesive layer can be present between the aluminum layer and one or more polymer layers. For example, an inner face of the aluminum layer can be coated with a lacquer layer, which can be, for example, PVC.

[0027] The materials and polymer preferably have a hardness less than or equal to 40 D Shore hardness, more preferably less than or equal to 30 D Shore hardness. Advantageously, the use of relatively soft polymers for the outer surface of the cup-shaped body allows the material to deform around imperfections and traces of a closure member to provide a more effective hydraulic seal.

[0028] One or more polymer layers may have a total thickness greater than or equal to 80 microns. A full thickness range of 80 microns to 300 microns can be used. However, a total thickness of 100 microns for one or more polymer layers has been shown to be particularly effective.

[0029] In one example, the sheet material (prior to embedding) comprises an aluminum layer comprising an 8011 grade aluminum alloy having a thickness of 100 microns in a coextruded polymer film 100 microns thick, providing a thickness total for 200 micron sheet. The co-extruded polymer film in this example is Flextrus WB 100ET available from Flextrus Ltd of Highbridge, UK, which is a multi-layer co-extruded film having a structure of PE - tie layer - EVOH - tie layer - PE .

Advantageously, the combination of a relatively soft polymer(s) of less Shore hardness less than or equal to 30 D with a total thickness of 100 microns beneficially results in a material that can deform sufficiently to form a seal around moderately sized imperfections and traces of a closure member without requiring too high a closure force on the closure member to operate.

[0031] The present disclosure also provides a beverage capsule formed by combining a cup-shaped body formed using the method described above and a cap. The beverage capsule can be filled with one or more beverage ingredients.

[0032] The cover can be sealed to the annular recess of the side wall. The cap can be sealed to an inner surface of a bottom of the annular trough.

[0033] As discussed above, the cup-shaped body of the present method can be used for producing a beverage capsule that can be inserted into a beverage preparation machine of the type having a closure member that fits into a flange of the inserted beverage capsule. In accordance with the present disclosure, the annular trough may be dimensioned to partially or fully receive an inlet edge of the closure member there on movement of the closure member to the closed position.

[0034] The sidewall can be adapted to undergo plastic deformation during closure of the closure member.

[0035] The sidewall can be adapted so that, in use, a closure of the closure member deforms the sidewall to cause the second sidewall section to be forced inward against an outer face of the closure member to form a sealing interface with the outer face of the closure member.

[0036] The annular trough can be adapted to form a sealing interface with the entry edge of the closure member.

[0037] Advantageously, a sealing interface can be provided with both the inlet edge and the outer face of the closure member. In addition, the deformation of the annular trough can also cause an external pressure to be exerted by the sidewall on the inner face of the closure member to form another sealing interface.

[0038] The sidewall can be adapted so that, during closing of the closure member, the sidewall is plastically recessed over the inlet edge of the closure member. Advantageously, this may allow the sidewall to be shaped to the shape of any grooves (or the like) provided in the lead-in edge.

[0039] In closing the annular trough, an inlet edge of the closing member may contact the outer wall of the annular trough and form a seal with it.

[0040] The crest zone may comprise an apex, and an entry edge of the closure member may comprise an inner rim and an outer rim and a recess located between the inner rim and the outer rim, wherein, in the closure of the member of closing, the apex of the crest zone can be received in the recess between the inner rim and the outer rim.

[0041] The annular trough can be adapted to be bitten against a capsule holder of the beverage preparation machine part.

[0042] Prior to insertion, a bottom of the annular trough can be raised against the rim. The bottom of the annular trough can be displaced from a distal end of the sidewall by a distance of 0.1 to 2.0 mm. In one example the offset may be relatively large, for example it may be 1.55 to 2.0 mm. In a specific example, the offset might be 1.85 mm. When the displacement is relatively large, the bottom of the annular trough may be 0.75 to 1.2 mm below an apex of the crest zone (when present). In an example, the distance could be 0.9 mm. In another example, prior to insertion, the bottom of the annular trough may be substantially flush with the rim. For example, the offset can be from 0.1 to 0.5 mm. In an example, the offset might be 0.2 mm. In this alternative arrangement, the bottom of the annular trough may be 2.0 to 2.5 mm below an apex of the crest zone (when present). In one example, the distance is 2.2 mm.

[0043] The sidewall can be adapted so that, in use, the closure of the closure member deforms the sidewall to cause the bottom of the annular trough to be placed substantially in alignment with the rim.

[0044] An entry edge of the closure member may comprise a plurality of grooves or recesses, and the side wall may be adapted so that the plastic deformation of the side wall conforming to the annular trough of the side wall to the grooves or recesses for provision of an effective seal. In one arrangement, the plastic deformation of the sidewall conforms the outer wall of the annular trough to grooves or recesses to provide an effective seal.

[0045] The lid can be formed from aluminium, an aluminum alloy or a laminate comprising at least one layer formed from aluminum or an aluminum alloy. Alternatively, another suitably ductile material could be used. The lid may further comprise a heat seal lacquer or a heat seal layer to improve the seal of the lid to the cup-shaped body.

[0046] Prior to insertion, the capsule may have a height of 25 to 31 mm. In some respects, the height can be from 28.5 to 31 mm. Capsule deformation during use will tend to reduce the longitudinal height.

[0047] Preferably, the cup-shaped bodies can be shaped so that they can be stacked and unstacked easily, prior to filling and assembly with the lids.

[0048] The capsule can form a single-use disposable element.

[0049] The capsule may contain a beverage ingredient or a mixture of beverage ingredients. As a non-limiting example, the beverage ingredient may comprise roasted ground coffee.

Brief Description of Drawings

[0050] The present disclosure will now be described in greater detail, for example purposes only, with reference to the associated drawings, in which: Figure 1 is a cross-sectional view of a first example capsule that may be formed of in accordance with the present disclosure; Figure 2 is an enlarged view of a detail of Figure 1; Figure 3 is a schematic illustration of the capsule of Figure 1 together with a closure member of a beverage preparation machine; Figure 4 is an enlarged view of a detail of Figure 3; Figure 5 is a schematic illustration of the arrangement of Figure 3 with the closure member in a closed position; Figure 6 is an enlarged view of a detail of Figure 5; Figure 7 is a cross-sectional view of a second example capsule that may be formed in accordance with the present disclosure; Figure 8 is an enlarged view of a detail of Figure 7; Figure 9 is a schematic illustration of the capsule of Figure 7 together with a closure member of a beverage preparation machine; Figure 10 is an enlarged view of a detail of Figure 9; Figure 11 is a schematic illustration of the arrangement of Figure 9 with the closure member in a closed position; Figure 12 is an enlarged view of a detail of Figure 11; Figure 13 is a cross-sectional view of a third example capsule that may be formed in accordance with the present disclosure; Figure 14 is an enlarged view of a detail of Figure 13; Figure 15 is a schematic illustration of the capsule of Figure 13 together with a closure member of a beverage preparation machine; Figure 16 is an enlarged view of a detail of Figure 15; Figure 17 is a schematic illustration of the arrangement of Figure 15 with the closure member in a closed position; Figure 18 is an enlarged view of a detail of Figure 17; Figure 19 is a schematic cross-sectional view of a section of a first probe for forming a cup-shaped body preform of a capsule; Figure 20 is a cross-sectional view of a cup-shaped body preform formed using the first probe of Figure 19; Figure 21 is an enlarged view of a portion of Figure 20; Figure 22 is a schematic cross-sectional view of a section of a second probe for transforming the preform from a cup-shaped body to a cup-shaped body for a capsule in a first position; Figure 23 is a cross-sectional view of a cup-shaped body formed using the second probe of Figure 22; and Figure 24 is an enlarged view of a portion of Figure 23.

Detailed Description

[0051] Figure 3 schematically shows a part of a beverage preparation system. The beverage preparation system comprises a beverage preparation machine and a capsule 1. Examples of capsules 1 made in accordance with the present disclosure will first be described and their use as part of such a beverage preparation system. Thereafter, a method of forming the capsules 1 - and in particular of forming parts of the capsules 1 will be described.

[0052] Figures 1 and 2 show a first example of capsule 1. The capsule 1 will be described in more detail below, but may have the general shape of a cup-shaped body 40 having a base 42 at one end and a wall side 43 which extends from the base 42 towards an opposite end which is closed by a cap 41.

[0053] As shown in Figure 3, the beverage preparation machine comprises a closure member 2 and a capsule holder 20. The closure member 2 is selectively movable relative to a capsule holder 20 between an open position, to allowing insertion of the capsule 1 into the beverage preparation machine, and a closed position in which the closure member 2 sealingly engages the capsule 1 against the capsule holder 20 in a manner which will be described below.

[0054] The closure member 2 can be moved between the open and closed positions by means of a conventional mechanism well known in the art. For example, the means may involve a mechanical mechanism activated by a manually movable lever or an automatic or semi-automatic mechanism in which a movement is commanded by a motor. The closure member 2 can be moved while the capsule holder 20 remains stationary. Alternatively, the closure member 2 can remain stationary and the capsule holder 20 be moved. In a further alternative arrangement, the closing member 2 and the capsule holder 20 can move during the opening and closing operations.

[0055] The closure member 2 and the capsule holder 20 in the closed position together define a receptacle 3 for maintaining the capsule 1 during a dispensing operation.

[0056] The beverage preparation machine may further comprise other conventional elements, which are not illustrated in the associated drawings and are well known in the beverage preparation machines art. For example, the beverage preparation machine may comprise an installation for storing an aqueous medium, such as an internal reservoir, or an installation for connecting to an external supply of an aqueous medium, such as tap water. The aqueous medium will typically be water. A pump or equivalent may be provided to supply the aqueous medium in a pressurized state to capsule 1. The aqueous medium will typically be supplied at a pressure of up to 9 to 14 bar (0.9 to 1.4 MPa). A heater can be provided for heating the aqueous medium to a desired temperature. The heater may heat the aqueous medium in the reservoir (when present) or may heat the aqueous medium on demand as it passes through a conduit or over a thermoblock to the receptacle 3. The beverage preparation machine may comprise a means of perforating base for perforating the base 42 of the capsule 1 to allow the aqueous medium to enter the capsule 1 and interact with the beverage ingredients therein. Alternatively, capsule 1 may be provided with one or more pre-formed openings to allow the entry of aqueous medium from receptacle 3 into capsule 1.

[0057] The closure member 2 may be of the type described in EP 1700548 comprising an annular element 22 having an inlet edge 23 in the form of an annular ring, an inner face 25 facing the receptacle 3 and an outer face 24 facing to the outside. The inlet edge 23 may be provided with a plurality of grooves as taught in EP 1700548. An upper end (not shown) of the closure member 2 may be coupled to a supply of aqueous medium and may provide a support for one or more piercing elements intended to pierce the base 42 of the capsule 1 in use.

[0058] The capsule holder 20 may be of the type described in EP 1700548 comprising relief elements 21 which are designed to tear and perforate the lid 41 of the capsule 1. The tearing of the lid 41 can occur due to an internal pressurization of the capsule. 1 caused by the aqueous medium flowing inwards. The relief elements 21 may be of any designed shape capable of causing a partial tearing of the sheet member, for example pyramids, needles, protrusions, cylinders or elongated ribs.

[0059] As shown in Figure 1, the cup-shaped body 40 and the lid 41 of the capsule 1 together enclose a beverage ingredient chamber 50, which can be filled with a beverage ingredient or a mixture of beverage ingredients. drink. As a non-limiting example, the beverage ingredient may comprise roasted ground coffee.

[0060] In the illustrated example, the cup-shaped body 40 is made from aluminum or an aluminum alloy. However, other materials can be used, such as an aluminum or aluminum alloy laminate and a polymer. The cup-shaped body 40 includes the base 42 and the sidewall 43. There may, as illustrated, be a geometric discontinuity at the junction between the base 42 and the sidewall 43, for example in the form of a bead 57. Alternatively, base 42 and sidewall 43 may have a smooth geometric transition.

[0061] The cup-shaped body 40 may have a thickness in the range of 80 to 500 microns. The material thickness can be varied throughout the cup-shaped body 40. In the illustrated example, the thickness is 100 microns.

[0062] The side wall 43 is provided with an annular trough 60, which is dimensioned to receive, partially or entirely, the inlet edge 23 of the closure member 2 in a movement of the closure member 2 to the closed position. A first side wall section 61 is provided extending between the base 42 and the annular trough 60 and a second side wall section 62 is provided extending between the annular trough 60 and a distal end of the side wall 43 of the capsule 1.

[0063] The annular trough 60 can be defined by an inner wall 65, an outer wall 66 and a bottom 64 extending between them. The inner wall 65 and the outer wall 66, prior to insertion of the capsule 1 into the beverage preparation machine, may extend perpendicularly to the bottom 64. The inner wall 65 may be formed by a portion of the first side wall section 61.

[0064] A crest zone 63 is located radially outward from the annular trough 60. The crest zone 63 may comprise an annular projection extending backwards in the general direction of the base 42, so that an apex 67 of the crest zone 63 is raised above the level of the bottom 64 of the annular trough 60. The apex 67 can be raised above the bottom 64 by a distance of 0.75 to 2.5 mm. As illustrated in this example, the distance is 0.9 mm. Ridge region 63 may be formed to have an inner wall provided by outer wall 66 of annular trough 60 and outer wall 68 formed by at least a portion of second side wall section 62.

[0065] The sidewall 43, including the annular trough 60 and the crest zone 63, can be formed integrally. Furthermore, the cup-shaped body 40 including the sidewall 43 and the base 42 can be formed integrally.

[0066] The annular trough 60 may have an internal width of 1.3 to 2.0 mm. Typically, the inner width of the annular trough 60 is chosen to be marginally greater than the amplitude of the lead-in edge 23 of the annular element 22. In one example, the annular trough 60 has an internal width of approximately 1.5 mm to 1, 8 mm.

[0067] The annular trough 60 may have an inner diameter of 27.5 to 30.0 mm (i.e. the diameter of the surface of the inner wall 65 facing the annular trough 60) and an outer diameter of 29.3 to 32 .5 mm (ie, the diameter of the surface of the outer wall 66 facing the annular trough 60). Optionally, the inner diameter can be chosen so that there is a slight interference fit between the inner wall 65 and the outer face 24 of the closure member 2 in the closure. This helps to ensure good alignment of the annular trough 60 with the closure member 2.

[0068] As illustrated, the lid 41 is sealed to the annular trough 60. In particular, the lid 41 is sealed to an inner surface of the bottom 64 of the annular trough 60. The bottom 64 of the annular trough 60 is elevated with respect to one end distal end of sidewall 43. Consequently, cap 41 is also elevated relative to the distal end of sidewall 43. Bottom 64 can be displaced from the distal end of sidewall 43 by a distance of 0.1 to 2.0 mm, as described previously. As illustrated, the offset is 1.85 mm. Sealing the lid 41 to the bottom 64 helps to ensure that the closure member 2 does not rest on a hollow portion of the capsule 1 so as to trap beverage ingredients between the inlet edge 23 and the capsule holder 20, which could have a detrimental effect on the fluid tightness of the seal.

[0069] The lid 41 can be formed from aluminium, an aluminum alloy or a laminate containing aluminum.

[0070] The first side wall section 61 may comprise a frusto-conical section 44 proximal to the base 42 and a cylindrical section 45 distal to the base 42, wherein a portion of the cylindrical section 45 forms the inner wall 65 of the annular trough 60.

The capsule 1 may be provided with a collar 47 formed at one end of the cup-shaped body 40 remote from the base 42, i.e. at the distal end of the sidewall 43. The collar 47 may be formed integrally with the body in the form of a cup 40. In the illustrated example, the rim 47 is formed by a rolled portion 48 of the sidewall 43.

[0072] In use of the beverage preparation system, the closure member 2 is first moved to the open position and the capsule 1 is inserted at a location between the capsule holder 20 and the closure member 2. The closure member 2 is then closed so as to sealably engage the closure member 2 with the capsule 1. During this step, the base 42 of the capsule 1 can be pierced by the piercing elements of the closure member 2.

[0073] A pressurized aqueous medium (which may be heated, at room temperature or cooled) is then fluid into the capsule 1 for producing a beverage from an interaction with the beverage ingredients. During this step, an internal pressurization of the beverage ingredient chamber 50 causes the lid 41 to be deformed outwardly against the relief elements 21 of the capsule holder 20, resulting in at least partial tearing of the lid 41, which opens a path. outlet from capsule 1 for the drink.

[0074] The beverage is then extracted for consumption.

[0075] As shown in Figures 5 and 6, during the step of closing the closure member 2 in relation to the capsule holder 20, the side wall 43 of the capsule 1 is contacted by the closure member 2 to deform the side wall 43. In particular, the inlet edge 23 enters the annular trough 60 and abuts the bottom 64 and/or the inner wall 65 and/or the outer wall 66. The bottom 64 is directed downwardly by the action of the closure member 2 to bite the bottom 64 (and the cap 41 sealed to the bottom 64) against the capsule holder 20. The inlet edge 23 can also act to pinch the material from the sidewall 43 during this movement, which consequently causes the zone of ridge 63 is inwardly pivoted to place the apex 67 of the ridge 63 and/or the outer wall 66 of the annular trough 60 in sealing engagement with the outer face 24 of the annular element 22, as shown in Figure 6. Form importantly, the starting point of contact between the lead-in edge 23 and the bottom 64 is axially spaced from the capsule holder 20 so that there is room for the sidewall 43 to deform downwardly towards the capsule holder 20 enough to allow pivoting inwardly of the crest region 63, before the side wall 43 is bitten against the capsule holder 20.

[0076] The induced movement of the sidewall 43 causes the sidewall 43 to undergo plastic deformation. In particular, as the sidewall 43 is deformed downwardly, the sidewall 43 (in particular, the portions of the annular trough 60) can be plastically embedded over the inlet edge 23 of the closure member 2, which encourages the material of the closure. side wall 43 to be shaped closely to the grooves of the inlet edge 23. Thus, the annular trough 60 can form a sealing interface with the inlet edge 23 of the closure member 2.

[0077] Furthermore, a deformation of the annular trough 60 can also cause an outward pressure to be exerted by the side wall 43 on the inner face 25 of the closure member 2, to form another sealing interface.

[0078] Figures 7 to 12 illustrate a second example of capsule 1. The features corresponding to those in the first example are denoted by corresponding reference symbols. The features from the first example and this example can be interchanged and combined as desired. Also, in the following description, only the differences between the examples will be described in detail. In other respects, the reader is directed to the description of the previous example.

[0079] The cup-shaped body 40 differs from that of the first example in the configuration and geometry of the annular trough 60. As in the first example, the annular trough 60 is dimensioned to receive, partially or entirely, the entry edge 23 of the member closure 2 in a movement of closure member 2 to the closed position. The inner wall 65 of the annular trough 60, as before, is substantially perpendicular to the bottom 64. However, in contrast, the outer wall 66 is angled relative to the bottom 64 so that an inner angle α at a junction between the bottom 64 and outer wall 66 is from 90° to 120°, preferably 105°.

[0080] The crest zone 63 is again located radially outward from the annular trough 60 and comprises an annular projection extending backwards in the general direction of the base 42 so that an apex 67 of the crest zone 63 is raised above from the level of the bottom 64 of the annular trough 60. The apex 67 can be raised above the bottom 64 by a distance of 0.75 to 2.5 mm. As illustrated in this example, the distance is 2.2 mm. The ridge region 63 may be formed to have an inner wall provided by the sloping outer wall 66 of the annular trough 60 and an outer wall 68 formed by at least a portion of the second side wall section 62. As shown more clearly in Figure 8, the second side wall section 62 may comprise between the outer wall 68 and the rolled portion 48 of the rim 47 an additional annular ridge 70 which may provide additional rigidity to the outer portion of the flange. The height of the additional annular crest 70 can be from 0.7 to 0.8 mm.

[0081] The sidewall 43 including the annular trough 60 and the ridge zone 63 can be formed integrally. Furthermore, the cup-shaped body 40 including the sidewall 43 and the base 42 can be formed integrally.

[0082] The annular trough 60 may have an internal width of 1.3 to 2.0 mm. As illustrated, the annular trough 60 has an internal width of approximately 1.5 mm to 1.8 mm.

[0083] As illustrated, the cap 41 is sealed to the annular trough 60. In particular, the cover 41 is sealed to an inner surface of the bottom 64 of the annular trough 60. The bottom 64 of the annular trough 60 is substantially flush with a distal end of the sidewall 43, prior to insertion. As illustrated, the displacement of the distal end of the sidewall 43 and cap is only 0.2 mm.

[0084] In a use of the beverage preparation system as shown in Figures 9 to 12, as before, the closure member 2 is first moved to the open position, and the capsule 1 is inserted into a location between the cap 20 and closure member 2. Figure 9 illustrates that the inlet edge 23 of closure member 2 may comprise an inner ring 23a and an outer ring 23b which are concentric and spaced apart to define a recess 23c between them, which may generally be annular (although it may have gaps around its circumference).

[0085] As shown in Figures 11 and 12, in closing the closure member 2 relative to the capsule holder 20, the side wall 43 of the capsule 1 is contacted by the closure member 2 to deform the side wall 43. In particular, the inner rim 23a of the lead-in edge 23 is received in the annular trough 60 and bears on the outer wall 66, while at the same time (or briefly thereafter) the apex 67 of the ridge region 63 is received in the recess 23c. The crest region 63 (and the bottom 64) is directed downwardly by the action of the closure member 2 on the outer wall 66 and/or the apex 67, causing the outer wall 66 of the annular trough 60 and the outer wall 68 of the ridge zone 63 bunch up and deform / dent. During this movement, the material of the outer wall 66 of the annular trough 60 can be plastically embedded over the inlet edge 23 to conform the outer wall 66 of the annular trough 60 to the grooves or recesses for the provision of an effective seal.

[0086] The downward movement of the ridge zone 63 also bites the bottom 64 (and the cap 41 sealed to the bottom 64) against the capsule holder 20, as shown in Figure 12.

[0087] The geometry of the outer wall 68 of the crest zone 63, with the additional annular crest 70, helps to stiffen the distal end of the side wall 43 and prevent the rim 47 from being deflected downwardly into contact with the capsule holder 20 .

[0088] A downward movement of the closure member 2 may continue beyond the point illustrated in Figure 12, until the inner ring 23a contacts and rests against the bottom 64 of the annular trough 60.

[0089] The perforation and preparation of a drink from the capsule 1 can be as described above in the first example.

[0090] Figures 13 to 18 illustrate a third example of capsule 1. The features corresponding to those of the first and/or the second example are denoted by corresponding reference symbols. The features of the first and/or second example and this example can be interchanged and combined as desired. Also, in the following description, only differences between the examples will be described in detail. In other respects, the reader is directed to the description of the above examples.

[0091] The cup-shaped body 40 differs from that of the first and second examples in the configuration and geometry of the annular trough 60. As in the second example, the annular trough 60 is dimensioned to receive, partially or entirely, the leading edge 23 of the closure member 2 in a movement of the closure member 2 to the closed position. The inner wall 65 of the annular trough 60 is substantially perpendicular to the bottom 64 and the outer wall 66 is inclined relative to the bottom 64 so that an inner angle α at a junction between the bottom 64 and the outer wall 66 is 90°. at 120°, preferably 105°.

[0092] The crest zone 63 is again located radially outward from the annular trough 60 and comprises an annular projection extending backwards in the general direction of the base 42, so that an apex 67 of the crest zone 63 is raised above from the level of the bottom 64 of the annular trough 60. The apex 67 can be raised above the bottom 64 by a distance of 0.75 to 2.5 mm. As illustrated in this example, the distance is 2.2 mm. The ridge region 63 may be formed to have an inner wall provided by the sloping outer wall 66 of the annular trough 60 and an outer wall 68 formed by at least a portion of the second side wall section 62. As shown more clearly in Figure 14, the outer wall 68 comprises three distinct sections - an upper section 73 which, before insertion, is perpendicular to the bottom 64, a middle section 71 which is inclined at an angle β from 20 to 80°, preferably 60° , with the vertical and a lower section 72 that includes a horizontal portion - parallel to the bottom 64 - before merging into the curled portion 48 of the rim 47.

[0093] The sidewall 43, including the annular trough 60 and the ridge zone 63, can be integrally formed. In addition, the cup-shaped body 40 including sidewall 43 and base 42 can be formed integrally.

[0094] The annular trough 60 may have an internal width of 1.3 to 2.0 mm. As illustrated, the annular trough 60 has an internal width of approximately 1.5 mm to 1.8 mm.

[0095] As illustrated, the cap 41 is sealed to the annular trough 60. In particular, the cover 41 is sealed to an inner surface of the bottom 64 of the annular trough 60. The bottom 64 of the annular trough 60 is substantially flush with a distal end of the sidewall 43, prior to insertion. As illustrated, the displacement of the distal end of the sidewall 43 and cap is only 0.2 mm.

[0096] In a use of the beverage preparation system as shown in Figures 15 to 18, as before, the closure member 2 is first moved to the open position, and the capsule 1 is inserted into a location between the capsule 20 and the closure member 2.

[0097] As shown in Figures 17 and 18, in closing the closure member 2 relative to the capsule holder 20, the side wall 43 of the capsule 1 is contacted by the closure member 2 to deform the side wall 43. In particular, the inner rim 23a of the lead-in edge 23 is received in the annular trough 60 and bears on the outer wall 66, while at the same time (or briefly thereafter) the apex 67 of the ridge region 63 is received in the recess 23c. The crest region 63 (and the bottom 64) is directed downwardly by the action of the closure member 2 on the outer wall 66 and/or the apex 67, causing the outer wall 66 of the annular trough 60 and the outer wall 68 of the ridge zone 63 bunch up and deform / dent. During this movement, the material of the outer wall 66 of the annular trough 60 can be plastically embedded over the inlet edge 23 to conform the outer wall 66 of the annular trough 60 to the grooves or recesses for the provision of an effective seal.

[0098] The downward movement of the crest zone 63 also bites the bottom 64 (and the cap 41 sealed to the bottom 64) against the capsule holder 20, as shown in Figure 12.

[0099] The geometry of the outer wall 68 of the crest zone 63, with the upper section 73, the middle section 71 and the lower section 72, helps to stiffen the distal end of the sidewall 43 and prevent the rim 47 from being deflected to low for contact with capsule holder 20.

[0100] A downward movement of the closure member 2 may continue beyond the point illustrated in Figure 12, until the inner ring 23a contacts and rests against the bottom 64 of the annular trough 60.

[0101] The piercing and preparation of a drink from the capsule 1 can be as described above in the first example.

[0102] The cup-shaped bodies 40 of the capsules 1 of the above examples are formed according to the following method.

[0103] Figure 19 illustrates a section of a first deep-flush probe 100 for forming a cup-shaped body preform 40. The first probe 100 comprises an upper half 101 and a lower half 102.

[0104] A cup-shaped body preform 40a is configured by shaping the tool pieces held in the upper half 101 and the lower half 102 and by their relative movement. The method of forming the cup-shaped body 40 comprises two sequential stages. In a first stage, a sheet of material is deeply embedded by the first probe 100 to form the cup-shaped body preform 40a. In a second and subsequent stage, the cup-shaped body preform 40a is transformed into the cup-shaped body 40 by further embedding the sheet material of the cup-shaped body preform 40a in a second probe 160 which will be further described below.

[0105] The upper half 101 of the first probe 100 may comprise a central upper tool surrounded by a cylindrical upper tool 105, both of which can be mounted on a upper frame. The top center tool may be shaped to shape an outer surface of the base 42 of the cup-shaped body preform 40a. The cylindrical top tool 105 is shaped for shaping an outer surface of the sidewall of the cup-shaped body preform 40a during the first stage of the swaging process.

[0106] The bottom half 102 of the first probe 100 can hold a center bottom tool surrounded by a cylindrical bottom tool 107, both of which can be mounted on a bottom frame. The central bottom tool (omitted from Figure 19 for clarity) may be shaped to form an inner surface of the base 42 and a side wall portion of the cup-shaped body preform 40a. The cylindrical bottom tool 107 is shaped for shaping an inner surface of a distal portion of the sidewall of the cup-shaped body preform 40a during the first stage of the swaging process.

[0107] In the first stage of the embedding process, a sheet of material, for example, an aluminum sheet, is positioned on the first probe 100, and the upper frame and lower frame are placed together for clamping the sheet of material between they. At this point, the sheet of material can be bitten between the distal ends of the cylindrical top tool 105 and the cylindrical bottom tool 107.

[0108] The center bottom tool is then commanded upwards into the cavity defined by the top half 101. Consequently, the sheet of material is embedded in the format shown in Figures 19 and 20 by an interfitting of the top center tool and the bottom tool center and fitting of the cylindrical top tool 105 and the cylindrical bottom tool 107 for forming the cup-shaped body preform 40a.

[0109] As seen more clearly in Figure 20, the cup-shaped body preform 40a comprises a base 42a and a preformed sidewall 43a, which extends from the base 42a to a rim 47a, which is rolled up.

[0110] The preformed sidewall 43a comprises an outwardly extending step 60a near the rim 47a, a primary sidewall section 61a extending between the base 42a and the outwardly extending step 60a, and a section of secondary sidewall 62a extending between the outwardly extending step 60a and the rim 47a. The outwardly extending step 60a is inclined 90° with a central longitudinal axis of the cup-shaped body preform 40a. Primary sidewall section 61a may comprise a frusto-conical section 44a proximal to base 42a and a cylindrical section 45a distal to base 42a. The portion of the secondary sidewall section 62a comprises a frusto-conical section which is divergent towards the rim 47a.

[0111] For the second stage of the embedding process, the second probe 160 is used, as shown in Figure 22. The second probe 160 comprises an upper half 161 and a lower half 162. The upper half 161 of the second probe 160 may comprise an upper central tool surrounded by an upper inner cylindrical tool 164, and an upper outer cylindrical tool 165. The upper central tool and upper inner cylindrical tool 164 can be oriented apart by springs. The top center tool can be shaped to form (or maintain the pre-formed shape of) an outer surface of the base 42 of the cup-shaped body 40 during the second stage of the swaging process. The cylindrical outer top tool 165 is shaped to shape a portion of the sidewall close to the rim during the second stage of the swaging process.

[0112] The lower half 162 of the second probe 160 maintains a center bottom tool 166 surrounded by a cylindrical bottom tool 167. The center bottom tool 166 is shaped to hold and support the cup-shaped body preform 40a during the second embedding stage and, in particular, to support an inner surface of a portion of the preformed sidewall. The cylindrical bottom tool 167 is shaped to shape a distal portion of the sidewall of the cup-shaped body preform 40a during the second stage of the swaging process.

[0113] During the second embedding stage, the cup-shaped body preform 40a is removed from the first probe 100 and positioned on the second probe 160 with the preform mounted on the center bottom tool 166. After positioning the cup-shaped body preform 40a on the second probe 160, the cylindrical inner top tool is replaced, and the second probe 160 is directed to the closed position, as shown in Figure 22. During a first closing movement, the tool cylindrical inner top tool 164 is moved relative to cylindrical outer top tool 165 until they contact each other. Thereafter, the cylindrical inner top tool 164 and the cylindrical outer top tool 165 move in unison. During a closure, a distal end 170 of the cylindrical inner top tool 164, which comprises a tapered and tapered ferrule 171, contacts the outwardly extending step 60a of the cup-shaped body preform 40a and directs the material from the rung down. A distal end 172 of the cylindrical bottom tool 167 comprises a ridge 120 between a lower inner bearing 119 and an intermediate outer bearing 121. The ferrule 171 is received within the ridge 120 so that, as shown in Figure 22, the rung which extends outwardly 60a (together with optionally a portion of the secondary sidewall section 62a) is bent to the desired shape as shown in Figures 23 and 24, which comprises the annular trough 60, the first sidewall section 61 extending between the base 42 and the annular trough 60, and the second side wall section 62 extending between the annular trough 60 and the rim 47. Further, the ridge 120 forms the ridge region 63 located radially outward of the annular trough 60.

[0114] The frusto-conical section 44a of the primary sidewall section 61a may be substantially or entirely unaffected by the transformation of the second stage and thus forms the frusto-conical section 44 of the first sidewall section 61 of the shaped body. 40 cup.

Claims (13)

1. Method of forming a cup-shaped body (40) for a beverage capsule, characterized in that it comprises the steps of: - ) in a first stage, the embedding of a sheet of material in a preform of cup-shaped body (40a); and - ) in a second stage, the transformation of the preform (40a) from a cup-shaped body to a cup-shaped body (40); wherein, after the first stage, the cup-shaped body preform (40a) comprises a base (42a) and a preformed sidewall (43a) extending from the base (42a) to a rim (47a); wherein the pre-formed sidewall (43a) comprises: - an outwardly extending step (60a) close to the rim (47a); - a primary sidewall section (61a) extending between the base (42a) and the outwardly extending step (60a); and - a secondary side wall section (62a) extending between the outwardly extending step (60a) and the rim (47a); wherein, in the second stage, the preformed sidewall (43a) is deformed so that the cup-shaped body (40) comprises the base (42) and a sidewall (43) extending from the base (42) to rim (47); wherein the side wall (43) comprises: - an annular trough (60); - a primary side wall section (61) extending between the base (42) and the annular trough (60); and - a second side wall section (62) extending between the annular trough (60) and the rim (47); wherein the secondary side wall section (62) defines a ridge zone (63) located radially outward of the annular trough (60) and the ridge zone (63) is formed during the second stage by deforming the extending step. outward (60a) and/or the secondary sidewall section (62a); and wherein the sheet material comprises an aluminum material. 2. Method according to claim 1, characterized in that the outwardly extending step (60a) is inclined at 90° with a central longitudinal axis of the cup-shaped body preform (40a). 3. Method according to claim 1, characterized in that the primary side wall section (61a) comprises a frusto-conical section (44a) close to the base (42a). 4. Method according to claim 3, characterized in that the frusto-conical section of the primary sidewall section (44a) (61a) is substantially or totally unaffected by the second stage transformation, and thereby forms a section taper of the section (44) of the primary sidewall (61). 5. Method according to any one of claims 3 or 4, characterized in that the primary sidewall section (61a) comprises a cylindrical section (45a) between the frusto-conical section (44a) and the outwardly extending step (60a). 6. Method according to claim 1, characterized in that the secondary side wall section (62a) comprises a frusto-conical section. 7. Method according to claim 6, characterized in that the frusto-conical section is divergent (47a). 8. Method according to claim 1, characterized in that the annular trough (60) comprises an inner wall (65), an outer wall (66) and a bottom (64). 9. Method according to claim 8, characterized in that the outer wall (66) is inclined relative to the bottom (64), so that an inner angle at a junction between the bottom (64) and the outer wall (66) is from 90° to 120°. 10. Method according to claim 1, characterized in that the outer wall (66) is inclined with respect to the bottom (64), so that an inner angle at a junction between the bottom (64) and the outer wall (66) is 105°. 11. Method according to claim 1, characterized in that the cup-shaped body preform (40a) is formed from an integral sheet of material. 12. Method according to claim 1, characterized in that the cup-shaped body preform (40a) is formed by deep embedding the sheet of material. 13. Method according to claim 12, characterized in that the cup-shaped body preform (40a) is formed by deep cold embedment of the sheet of material.

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